Method and apparatus for repairing the rail of a split rail fence

ABSTRACT

An apparatus for repairing the rail of a split-rail fence having a broken tapered end portion. The apparatus has elongate, hollow sleeve with a base portion and a tapered end portion. The base portion and end portion have a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively, and have interior cross-sectional dimensions that are larger than the exterior cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively. The sleeve can slide over and encase the tapered end and at least a portion of the central base portion of the rail. The apparatus preferably includes means for fastening the base portion of the sleeve to the base portion of the rail.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. provisional application No. 61/516,690 entitled Rail Saver, filed Apr. 6, 2011, which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to fence repair and, more particularly, repair of the horizontal rails of a split-rail fence.

BACKGROUND OF THE INVENTION

Traditionally, agricultural and residential split-rail fencing has been constructed from wood. Such fencing typically comprises a plurality of vertical fence posts installed in the ground at standard intervals, and a plurality of horizontal rails connecting each post. The horizontal rails have roundish central portions and tapered ends. The rails are connected to the posts by inserting the tapered ends through bore holes in the post.

Over time, the entire fence is subjected to prolonged exposure to moisture, weather, dry rot, insects, and external forces placed on it by animals, people, and falling objects. Since the entire wooden fence is subject to the same adverse environmental conditions, the fence typically breaks at its structurally-weakest point, namely, its tapered ends. When this occurs, the posts and other rails of the fence may still be structurally sound. In such case, only one particular rail needs repair or replacement.

In the past when a fence rail broke or become weakened, it was necessary to replace the rail with a new rail, which can be costly as multiple rails of a long fence require repair. Furthermore, because the length of the rails is greater than the distance between posts, replacing a rail can be difficult if the fence posts are firmly set in the ground and have no leeway to sway back and forth.

One proposed solution to rail replacement is to use an alternative wood variety, such as redwood, that has greater durability. However, such woods are typically much more expensive. Instead, some land owners attempt to splice or mend broken fence rails with varying degrees of success. However, rail repair is beyond the skill level of may agricultural land owners and most residential land owners. Therefore, it would be desirable to provide an apparatus and method for repairing the broken ends of split-rail fencing rails that is inexpensive and easy to install.

SUMMARY OF THE INVENTION

The invention provides an apparatus and method of repairing the horizontal rail of a split-rail fence that has broken at its tapered end. The apparatus restores the length of a broken rail to its original length in minutes and can be installed without the use of tools of any kind The apparatus eliminates the need to purchase an entirely new rail.

The apparatus generally comprises an elongate, hollow sleeve having a base portion and a tapered end portion. The base portion and end portion have a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively. The base portion and end portion have interior cross-sectional dimensions that are larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail. In preferred embodiments, the apparatus also has means for fastening the base portion of the sleeve to the base portion of the rail.

The tapered end of the sleeve is constructed and arranged to replace the broken tapered end portion of the rail and allow the rail to be re-installed on a split-rail fence post. The elongate sleeve has a uniform cross section along the central base portion and a cross-section that preferably tapers in two dimensions along the length of the sleeve. The elongate sleeve has open proximal and distal ends.

In one embodiment, the fastening means comprises at least one aperture extending through the base portion of the sleeve and a fastener extending through the aperture. In another embodiment, the fastening means comprises a threaded aperture extending through the base portion of the sleeve, and a hand-tightenable, threaded fastener engaging the aperture. In this embodiment, the threaded fastener may comprise a thumb screw.

In a further embodiment, the fastening means comprises an aperture extending through the base portion of the sleeve, a threaded anchor coaxial with the aperture, and a threaded fastener engaging the anchor. The anchor may be fixed in or adjacent the aperture. Preferably, the threaded fastener has an enlarged head at one end for hand tightening the fastener and a foot at the other end having a cross section larger than the cross section of the shank of the fastener.

In yet an additional embodiment, the fastening means may comprise a plurality of shims.

A method is also provided for repairing a split-rail fence rail having a first end and a second broken tapered end on a fence having immovable posts using the novel repair sleeve. Initially, the broken tapered end portion is completely removed from the rail if the rail was only fractured. The sleeve is then installed by axially sliding the repair sleeve over the broken end of the rail toward the center of the rail until the end of the rail abuts the interior of the tapered end portion of the sleeve. The unbroken end of the rail is then inserted into an aperture of a first post. The second end of the rail bearing the repair sleeve is then located adjacent an aperture in a second post. The sleeve is axially slid away from the center of the rail until the tapered end engages the post aperture. The repair sleeve is then fixed to the central portion of the rail using one of the fixing means.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation of a split-rail fence that has been repaired with the repair apparatus in accordance with an embodiment of the invention;

FIGS. 2A an 2B are enlarged sectional views of the repair apparatus of FIG. 1 shown in the retracted and extended positions, respectively, during installation;

FIG. 3 is a perspective view of the repair apparatus of FIG. 1;

FIGS. 4 and 4A are a side elevation and enlarged, fragmentary cross-sectional views of a repair apparatus in accordance with another embodiment of the invention;

FIG. 5 is a fragmentary cross-sectional view of a repair apparatus in accordance with a further embodiment of the invention;

FIG. 6 is a fragmentary cross-sectional view of a repair apparatus in accordance with an additional embodiment of the invention;

FIG. 7 is a fragmentary cross-sectional view of a repair apparatus in accordance with a further embodiment of the invention;

FIG. 8 is a fragmentary cross-sectional view of a repair apparatus in accordance with yet a further embodiment of the invention; and,

FIG. 9 is a fragmentary cross-sectional view of a repair apparatus in accordance with a further embodiment of the invention;

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The repair apparatus of the present invention is described below with reference to FIGS. 1-9, wherein like reference numerals are used throughout to designate like elements. As used herein, the terms “hand installed”, “by hand”, and “hand-tightenable” shall mean without the use of tools of any kind As used herein, the term “split-rail fence rail” shall mean the rail component of a split-rail fence that has a central base portion and opposed tapered end portions.

A repair apparatus in accordance with a first preferred embodiment of the present invention is designated generally by reference numeral 9. The apparatus 9 is designed for repairing the rail 8 of a split-rail fence 5 having a plurality of vertical support posts 6. The rails 8 have a central base portion 8 a and opposed, tapered end portions 8 b, which are inserted through apertures 7 in each post. The apparatus 9 is designed for the common scenario wherein the rail has broken along one of the tapered end portions 8 b, thereby forming a jagged broken end 8 c as seen in FIGS. 1-3.

In a first preferred embodiment shown in FIGS. 1-4, the repair apparatus 9 comprises an elongate, hollow sleeve 10 having a base portion 12 and a tapered end portion 14. Referring to FIG. 3, the base portion 12 of the sleeve 10 has a top wall 12 a, bottom wall 12 b, side walls 12 c,12 d, and an open proximal end 12 e. In this embodiment, the cross section of the base portion is rectangular and approximates and compliments the shape of the central bas portion of the fence rail 8 a. However, the cross section of the more roundish or irregularly shaped to approximate the shape of the central portion 8 a of the rail 8.

The tapered end portion 14 of the sleeve 10 has a top wall 14 a, bottom wall 14 b, side walls 14 c,14 d, and an open distal end 14 e. The cross section of the tapered end portion 14 approximates and compliments the shape of the tapered end portion of an unbroken fence rail 8 b. The cross section of the tapered end portion 14 gradually reduces in two dimensions extending from the base portion-tapered portion interface to the distal open end 14 e.

In a preferred embodiment, the interior cross-sectional dimensions of the sleeve are slightly larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail. For example, the length of the base portion 12 may be about 12 in. while the length of the tapered portion 14 may be about 10 in. The base portion 12 may be about 4 in. high and about 2.5 in. wide. The tapered portion 14 tapers to a height of about 3 in. and a width of about 1 in. or less so that the tapered end can fit into the preexisting apertures 7 in the fence posts 6. These dimensions allow for a generous tolerance in the outer dimensions of the fence rail 8 over which the sleeve will be installed. The wall thickness will vary depending on the material from which the sleeve is formed. If the material is made from a high density UV resistant plastic, the wall thickness may be in the range of 0.060-0.070 in.

In one preferred embodiment, the sleeve 10 is dimensioned to snugly fit over the tapered end portion 8 b of the rail and be held in place by friction created by an interference fit and/or friction created by the weight of the rail 8 on the interior of the sleeve 10 once the rail is re-installed on the fence. Alternatively, the sleeve 10 could be adhered to the post 8 after it is installed.

In another preferred embodiment, the sleeve 10 includes mechanical means for fastening the base portion 12 of the sleeve 10 to the base portion 8 a of the rail 8. Referring to FIGS. 4 and 4 a, the fastening means in this embodiment comprises one or more small holes 16 extending through the wall of the sleeve 10 in the base portion 12 proximate the open end 12 e. The hole 16 should be just large enough to allow insertion of a common fastener 18, such as a nail, wood screw, deck screw, etc, to be inserted and driven into the rail 8, but small enough that the head of the fastener 18 does not pass through the hole 16.

In the embodiment shown in FIGS. 4 and 4 a, a hand tool would be needed to install the fastener 18. In another preferred embodiment, the sleeve 10 includes mechanical fastening means that can be installed completely by hand. Referring to FIG. 5, the fastening means in this embodiment comprises a threaded hole 116 extending through the base portion 112 a wall of the sleeve 110, and a thumb screw 118 that engages the hole 116. The thumb screw 118 has an enlarged head 118 a that enables the user to tighten the thumb screw 118 by hand in contact with the base portion 8 a of the rail 8. In this embodiment, the remaining design features of the sleeve 110 are similar in all other aspects to the sleeve 10 described above with respect to FIGS. 1-3.

In another embodiment shown in FIG. 6, the fastening means comprises a hole 216 extending through the base portion 212 a of the sleeve 210, a threaded anchor 220 fixed adjacent to and coaxial with the hole 216, and a thumb screw 218 that extends through the hole 216 and engages the threaded anchor 220. The threaded anchor 220 may comprise, for example, a standard hex nut that is adhered to the inner surface of the sleeve 210. In this embodiment, the remaining design features of the sleeve 210 are similar in all other aspects to the sleeve 10 described above with respect to FIGS. 1-3.

In an additional embodiment shown in FIG. 7, the fastening means comprises a hole 316 extending through the base portion 312 a of the sleeve 310, a threaded anchor 320 fixed in and coaxial with the hole 316, and a thumb screw 318 that engages the threaded anchor 320. The threaded anchor 320 may comprise, for example, a T-nut that is adhered to the inner surface of the sleeve. Other threaded anchors could include a captive nut, molly bolt, cage nut or clinch nut. In this embodiment, the head of the threaded anchor is recessed in the inner surface of the base portion 312 a of the sleeve to avoid interference or impingement on the rail 8. In this embodiment, the remaining design features of the sleeve 310 are similar in all other aspects to the sleeve 10 described above with respect to FIGS. 1-3.

In a further embodiment shown in FIG. 8, the fastening means comprises a threaded hole 416 extending through the base portion 412 a of the sleeve 410, and a thumb screw 418 that engages the threaded hole 416. In this embodiment, the thumb screw 418 has an enlarged head 418 a for hand tightening. The distal end of the thumb screw 418 also includes a foot 422 having a cross section larger than the cross section of the shank of the thumb screw 418, which prevents the distal end of the thumb screw from impaling the rail 8. In this embodiment, the remaining design features of the sleeve are similar in all other aspects to the sleeve 10 described above with respect to FIGS. 1-3.

In yet a further embodiment shown in FIG. 9, the fastening means comprises one or more shims 524 that are inserted between the sleeve and rail 8 after the sleeve 510 is positioned on the rail 8. The shims can be inserted by hand or using a striking tool to increase the snugness of the fit. In this embodiment, the remaining design features of the sleeve 510 are similar in all other aspects to the sleeve 10 described above with respect to FIGS. 1-3.

The sleeve may be made of a variety of materials, including polymers and metals, having sufficient strength to support the rail and its intended design load. Preferably, the sleeve is also made of a material that is corrosion resistant. In a preferred embodiment, the sleeve is made from UV plastic that is blow molded.

A method of repairing a split-rail fence rail using the above-described repair sleeve is described with reference to FIGS. 2A and 2B. The repair sleeve 10 is useful for repairing a rail 8 having a first un-broken end and a second broken end 8 c, and which was previously installed in a fence having posts 6 that are immovable without disturbing or removing the footing in which the posts are set.

Initially, the user should remove, i.e., completely sever, the distal tip of the broken end if fractured but still intact. Then, the repair sleeve is installed by axially sliding the sleeve 10 over the broken end 8 c of the rail 8 toward the center of the rail until the end of the rail abuts the interior of the tapered end portion of the sleeve as best seen in FIG. 2A. The first end (un-broken end) of the rail is then inserted into an aperture 7 of a first post 6. The broken end 8 c of the rail 8 bearing the repair sleeve is then located adjacent an aperture 7 in an opposed second post 6. Because the repair sleeve is in the retracted position shown in FIG. 2A, a clearance is created between the distal end of the repair sleeve and the post 6, which would typically not be possible if a new, full-length rail was installed. Once the repair sleeve is aligned with the aperture 7, the repair sleeve is slid axially away from the center of the rail until the tapered end 14 engages the post aperture 7 as seen in FIG. 2B. The sleeve may then be affixed to the rail to prevent further axial movement of the sleeve by tightening any one of the fixing means described above.

The above-described method is especially useful when the posts 6 are firmly set in the ground and provide no leeway to move laterally along the fence line. If the posts 6 are loosely set in the ground, the repair sleeve 10 may be installed in the extended position shown in FIG. 2B before the rail is re-installed on the posts. Using this technique, the fence post would be forced laterally to create an alignment gap, such as shown in FIG. 2A, between the repair sleeve and post aperture 7 before inserting the rail in the aperture.

The apparatus 9 and method of the present invention provide a less expensive alternative to replacing an entire fence rail. Furthermore, since the apparatus 9 is small and compact, one or more can be conveniently stored in a shed, barn or garage using much less space than a full replacement rail. The apparatus can be installed quickly and easily without tools and with minimal effort on the part of the user.

While the principles of the invention have been described above in connection with specific embodiments, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of the invention. For example, it is conceived within the scope of the present invention that the repair sleeve could be applied to the ends of a fence rail that is not broken to reinforce the fence rail at those locations. This application of the invention has particular use along areas of the fence that experience frequent, excess loads, wear, or deterioration due to external forces. The apparatus may also be used to repair fence rails made of concrete, plastic or metal. 

1. An apparatus for repairing a split-rail fence rail having a broken tapered end portion, comprising: a) an elongate, hollow sleeve having a base portion and a tapered end portion, said base portion and end portion having a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively, and having interior cross-sectional dimensions that are larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail; and b) means for fastening the base portion of the sleeve to the base portion of the rail.
 2. The apparatus recited in claim 1, wherein the tapered end of the sleeve is constructed and arranged to replace the broken tapered end portion of the rail and allow the rail to be re-installed on a split-rail fence post.
 3. The apparatus recited in claim 1, wherein the elongate sleeve has a uniform cross section along the central base portion and a cross-section that tapers in at least two dimensions along the length of the sleeve.
 4. The apparatus recited in claim 3, wherein the elongate sleeve has an open proximal and distal ends.
 5. The apparatus recited in claim 1, wherein said fastening means comprises at least one aperture extending through the base portion of said sleeve and a fastener extending through said aperture.
 6. The apparatus recited in claim 1, wherein said fastening means comprises a threaded aperture extending through the base portion of said sleeve, and a hand-tightenable, threaded fastener engaging said aperture.
 7. The apparatus recited in claim 6, wherein said threaded fastener comprises a thumb screw.
 8. The apparatus recited in claim 1, wherein said fastening means comprises an aperture extending through the base portion of said sleeve, a threaded anchor coaxial with said aperture, and a threaded fastener engaging said anchor.
 9. The apparatus recited in claim 8, wherein said anchor is fixed in said aperture.
 10. The apparatus recited in claim 9, wherein said anchor is fixed adjacent to said aperture.
 11. The apparatus recited in claim 8, wherein said threaded fastener has an enlarged head at one end for hand tightening the fastener and a foot at the other end having a cross section larger than the cross section of the shank of the fastener.
 12. The apparatus recited in claim 1, wherein said fastening means comprises a plurality of shims.
 13. A method of repairing a split-rail fence rail having a first end and a second broken tapered end portion on a fence having immovable posts, comprising the steps of: a) providing an elongate, hollow repair sleeve having a base portion and a tapered end portion, said base portion and end portion having a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively, and having interior cross-sectional dimensions that are larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail; b) removing the broken tapered end portion from the rail; c) axially sliding the repair sleeve over the broken end of the rail toward the center of the rail until the end of the rail abuts the interior of the tapered end portion of the sleeve; d) inserting the first end of the rail into an aperture of a first post; e) locating the second end of the rail bearing the repair sleeve adjacent an aperture in a second post; f) axially sliding the repair sleeve away from the center of the rail until the tapered end engages the post aperture; and g) fixing the base portion of the repair sleeve to the central portion of the rail.
 14. An apparatus for repairing a split-rail fence rail having a broken tapered end portion, comprising and an elongate, hollow sleeve having a base portion and a tapered end portion, said base portion and end portion having a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively, and having interior cross-sectional dimensions that are larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail. 